Casing-free insulation blanket

ABSTRACT

An insulation blanket comprises (a) substantially hydrophobic insulation material; and (b) high temperature-resistant material; with the proviso that the blanket is casing-free.

STATEMENT OF PRIORITY

[0001] This application claims the priority of U.S. ProvisionalApplication No. 60/477,080 filed Jun. 9, 2003, the contents of which arehereby incorporated by reference.

FIELD

[0002] This invention relates to insulation blankets for use as thermaland/or acoustic shielding in, for example, transportation vehicles suchas aircraft. In other aspects, this invention also relates to processesfor preparing the blankets, to blankets produced thereby, and toinsulation processes.

BACKGROUND

[0003] Blankets providing thermal and/or acoustic insulation are used inaircraft and other vehicles to shield passengers from engine andaerodynamic noise and from temperature extremes. One problem with suchblankets is moisture uptake. This problem is particularly significant inaircraft, where weight increases due to water entrapment in the blanketscan be dramatic. Not only is moisture uptake undesirable from aneconomical standpoint, but it causes other problems as well. Theseproblems include reduced thermal and acoustic performance, reducedservice life for the blanket, and increased potential for corrosion onthe aluminum skin and framing of the aircraft.

[0004] Insulation blankets for aircraft are typically comprised of afibrous lofted insulation such as fiberglass batting encased within aprotective covering. The protective covering is typically made from twopieces of light-weight, tear-resistant, reinforced polymer film.Although the protective covering can facilitate blanket installation andalso serve to protect the insulation from damage during the installationprocess, its primary purpose is to prevent moisture from being taken upand retained by the insulation during the service life of the blanket.The protective covering, however, increases blanket cost and weight.

[0005] The labor-intensive method of blanket construction that istypically used further increases cost. The method involves cutting twoseparate pieces of polymer film to a size slightly larger than that ofthe insulation to be contained, so as to form selvedges. The two piecesof film are then sealed along the selvedges (for example, by sewing, byapplication of adhesive, or by heat sealing) to encase the insulation.

SUMMARY

[0006] Thus, we recognize that there is a need for insulation blanketsthat exhibit relatively low moisture uptake, that are relatively lightin weight and low in cost, and that can be simply and cost-effectivelyproduced without the need for labor-intensive, multiple process steps.

[0007] Briefly, in one aspect, this invention provides such aninsulation blanket, which comprises (a) substantially hydrophobicinsulation material; and (b) high temperature-resistant material; withthe proviso that the blanket is casing-free. The insulation materialpreferably comprises polymer (more preferably, it comprises polyolefin).Preferably, the insulation material is fibrous. The hightemperature-resistant material is preferably a flame-resistant material(more preferably, a burnthrough-resistant material).

[0008] It has been discovered that insulation blankets can functioneffectively without the need for a protective covering or casing whensubstantially hydrophobic insulation material is utilized in theirconstruction. For example, fibrous insulation made from substantiallyhydrophobic polymer such as polypropylene exhibits little moistureuptake and substantially maintains its thermal and acoustic performancewithout the need for a casing. In spite of the organic nature of suchinsulation material, the requisite thermal insulation characteristics ofthe blanket can be achieved by the addition of hightemperature-resistant material (for example, fiberglass paper or ceramicpaper) to the blanket construction. Surprisingly, by appropriateselection of the high-temperature resistant material, the blanket caneven be rendered burnthrough-resistant.

[0009] Since the insulation blanket of the invention is casing- orbag-free, it can be easily and cost-effectively manufactured bycontinuously bringing together its component layers, without the needfor separate, labor-intensive cutting, assembling, and sealing steps.The blanket can be made in the form of wide panels or webs that areconformable to vehicle surfaces and that enable installation with only aminimal number of seams, reducing the need for taping to prevent flamepropagation. Thus, the blanket meets the need in the art forthermal/acoustic insulation blankets that exhibit relatively lowmoisture uptake, that are relatively light in weight and low in cost,and that can be simply and cost-effectively produced and installedwithout the need for labor-intensive, multiple process steps.

[0010] In other aspects, this invention also provides the following:

[0011] an encased version of the insulation blanket (for ultimatemoisture exclusion yet burnthrough resistance) comprising (a)substantially hydrophobic insulation material comprising at least onepolymer (preferably, polyolefin; more preferably, polypropylene), and(b) burnthrough-resistant material, the materials being encased within aprotective covering;

[0012] a process for producing the insulation blankets of the invention,the process comprising the step of continuously bringing together,optionally in the presence of one or more intervening or adjacentmaterials, at least one insulation material and at least one hightemperature-resistant material;

[0013] a blanket produced by the process, wherein the materials are inthe form of layers that are substantially coextensive; and

[0014] a process for insulating a surface, the process comprising thestep of providing the surface with an insulation blanket of theinvention.

DETAILED DESCRIPTION

[0015] Definitions

[0016] As used in this patent application:

[0017] “substantially hydrophobic” means having hydrophobicity greaterthan or equal to that of untreated linear polyethylene (M_(n)=∞) (asevidenced by measurements of contact angle or surface tension such asthose compiled in Polymer Handbook, Fourth Edition, edited by J.Brandrup, E. H. Immergut, and E. A. Grulke, John Wiley & Sons, New York(1999));

[0018] “high temperature-resistant material” means a material that doesnot melt, flow, decompose, or otherwise substantially change shape attemperatures up to at least about 500° C.;

[0019] “casing-free” in reference to an insulation blanket means thatthe insulation material of the blanket is not encased in a protectivecovering (that is, although the blanket can comprise exterior protectivelayers, these protective layers are not directly sealed to each other(that is, are not sealed to each other in the absence of interveninginsulation material) so as to substantially fully enclose theinsulation);

[0020] “substantially coextensive” in reference to the component layersof an insulation blanket means that, if the blanket has exteriorprotective layers, the exterior protective layers do not extend beyondthe insulation layer(s) of the blanket so as to form selvedges fordirect sealing of the exterior protective layers to each other in theabsence of intervening insulation layer(s);

[0021] “lofty” in reference to a material means a fluffy material that,after application and removal of a compressive force, substantiallyresumes its original shape;

[0022] “flame-resistant material” means a material that meets theflammability requirements of the Federal Aviation Administration setforth at 14 C.F.R. Part 25, Sections 25.853(a) and 25.855(d) (whichreference Part I of Appendix F to Part 25), the texts of which areincorporated herein by reference;

[0023] “flame propagation-resistant material” means a material thatmeets the flammability requirements of the Federal AviationAdministration set forth at 14 C.F.R. Part 25, Section 25.856(a) (whichreferences Part VI of Appendix F to Part 25), the texts of which areincorporated herein by reference;

[0024] “flame penetration-resistant material” means a material thatmeets the flammability requirements of the Federal AviationAdministration set forth at 14 C.F.R. Part 25, Section 25.856(b) (whichreferences Part VII of Appendix F to Part 25), the texts of which areincorporated herein by reference; and

[0025] “burnthrough-resistant material” means a material that meets theflammability requirements of the Federal Aviation Administration setforth at 14 C.F.R. Part 25, Sections 25.853(a) and 25.855(d) (whichreference Part I of Appendix F to Part 25), as well as those set forthat 14 C.F.R. Part 25, Sections 25.856(a) (flame propagation)and25.856(b) (flame penetration) (which reference Parts VI and VII,respectively, of Appendix F to Part 25), the texts of which areincorporated herein by reference.

[0026] Substantially Hydrophobic Insulation Material

[0027] Insulation materials suitable for use in the insulation blanketof the invention are those that are more hydrophobic than untreatedlinear polyethylene, as evidenced by measured parameters known tocorrelate with hydrophobicity (for example, contact angle or surfacetension measurements). Such materials include substantially hydrophobicpolymers such as polyolefins (for example, polyethylene andpolypropylene) and the like, and substantially hydrophobic blendsthereof with each other and/or with other polymers. Other lesshydrophobic materials can also be utilized, provided that they aretreated to increase their hydrophobicity to greater than that ofuntreated linear polyethylene. Such hydrophobicity treatments caninvolve, for example, the use of silicones or fluorochemicals as topicaltreatments or polymer melt additives. Substantially hydrophobic polymersor other materials can also be treated, if desired, to further enhancetheir hydrophobicity characteristics. Preferably, the insulationmaterial comprises or consists essentially of at least one polymer (morepreferably, it comprises or consists essentially of at least onepolyolefin; most preferably, it comprises or consists essentially ofpolypropylene).

[0028] Blends of polypropylene and polyethylene terephthalate (PET) canbe used to prepare useful insulation material. Preferably, the blendscomprise at least about 50 percent polypropylene (more preferably, atleast about 55 percent; even more preferably, at least about 65 percent;most preferably, at least about 80 percent). Lesser amounts ofpolypropylene can be utilized, however, when hydrophobicity treatmentsare applied.

[0029] The insulation material can be in the form of fibrous insulation,foam insulation, or combinations thereof, with lofty fibrous insulationbeing preferred. Such materials can be manufactured by known methods.Suitable fibrous materials include, for example, the melt blown fiberscomprising polypropylene that are commercially available from 3M Companyof St. Paul, Minn. under the trade designation THINSULATE. Fibrousinsulation can be provided in the form of a lofty non-woven layer or matin which the fibers are entangled with or bonded to each other. Suchmats can be prepared according to conventional techniques such as meltblowing, air laying, or carding. The mats can be made with thermobondingfibers and exposed to heat to cause the thermobonding fibers to softenand bind at least some of the fibers together.

[0030] An example of a useful lofty nonwoven mat is described in U.S.Pat. No. 4,837,067 (Carey et al.), the description of which isincorporated herein by reference. As described therein, the mat consistsof a combination of entangled staple fibers and bonding staple fiberswhere the bonding fibers have, for example, a core of polyethyleneterephthalate surrounded by a sheath of an adhesive polymer formed fromisophthalate and terephthalate esters.

[0031] Other useful fibrous nonwoven webs are those that comprise acollected mass of directly-formed fibers disposed within the web in aC-shaped configuration, and crimped staple fibers dispersed within theweb to give the web loft and uniformity. Such directly-formed fibers arefibers formed and collected as a web in essentially one operation, forexample, by extruding fibers from a fiber-forming liquid (for example,molten or dissolved polymer, glass, or the like) and collecting theextruded fibers as a web. “C-shaped configuration” means that the fibersare assembled or organized in the web so that, when the web is viewed ina vertical, longitudinal cross-section, a representative individualdirectly-formed fiber is seen to include a) a segment or segmentsdisposed within the web transversely to the faces of the web (thissegment(s) forms the vertical portion of the “C”), and b) other segments(the arms of the “C”), which are connected to the transverse segment(s),are substantially parallel to the opposite faces of the web, and extendfrom the transverse segment in a direction opposite from the “machinedirection” of the web (the direction in which the web moved duringformation).

[0032] Other known insulation constructions can also be utilizedincluding, for example, the thermally insulating sheet materialdescribed in U.S. Pat. No. 4,136,222 (Jonnes), the description of whichis incorporated herein by reference.

[0033] High Temperature-Resistant Material

[0034] Suitable high temperature-resistant materials for use in theinsulation blanket of the invention include ceramic papers (for example,aluminosilicate ceramic fiber papers commercially available as KAOWOOLPaper from Thermal Ceramics, Inc., Augusta, Ga., and under the tradedesignation LYTHERM Paper from Lydall, Inc. of Rochester, N.H., as wellas a ceramic fiber paper encapsulated in polyimide film available as 3MNEXTEL Flame Shield AL-1 from 3M Company, St. Paul, Minn.), wovenceramic fibers (for example, fabrics commercially available under thetrade designation NEXTEL 312 AF-10 Aerospace Fabric from 3M Company, St.Paul, Minn.), woven fiberglass fibers (for example, fabrics commerciallyavailable under the trade designation SILTEMP Silica Fabric Type 84CHfrom Ametek of Wilmington, Del.), ceramic non-woven scrims (for example,scrims prepared from ceramic oxide fibers commercially available underthe trade designation NEXTEL 312 Ceramic Fibers from 3M Company, St.Paul, Minn.), and fiberglass non-woven scrims. Such materials can bemanufactured by known methods. Suitable high temperature-resistantmaterials include those described in U.S. Pat. No. 6,670,291 (Tompkinset al.), the description of which is incorporated herein by reference.

[0035] Preferred high temperature-resistant materials areflame-resistant materials (for example, aluminosilicate ceramic fiberpapers and S-glass paper). More preferred high temperature-resistantmaterials are both flame propagation-resistant and flamepenetration-resistant. Most preferred high temperature-resistantmaterials are burnthrough resistant materials (for example, ceramicpapers such as 3M NEXTEL Flame Stopping Dot Paper, available from 3MCompany, St. Paul, Minn., and vermiculite-coated ceramic paper availableas 3M NEXTEL Flame Stopping Coated Paper from 3M Company, as well asNOMEX Type 418 Paper available from DuPont, Richmond, Va.).

[0036] Additional Materials or Layers The insulation blanket of theinvention can comprise one or more layers of substantially hydrophobicinsulation material and one or more layers of high-temperature resistantmaterial. In addition, other materials and layers conventionally foundin insulation blankets can be included. For example, the blanket canfurther comprise one or more adhesive compositions or films, one or morescrims (for example, woven polymeric fabric), one or more waterrepellent coatings, one or more intumescent additives or coatings, andone or more polymer films (which can optionally be metallized), as wellas flame retardants, antistatic agents, anti-mildew agents, and thelike. When casing-free blankets are desired, however, the additionalmaterials and/or layers are preferably selected so as to notsignificantly increase the moisture uptake and retention characteristicsof the blanket.

[0037] Production, Installation, and Use of Insulation Blanket

[0038] The insulation blankets of the invention can be prepared by knownmethods such as those described in U.S. Pat. No. 5,624,726 (Sanocki etal.), the description of which is incorporated herein by reference.Preferably, the blankets are prepared by a continuous process that issimpler and more cost-effective than prior methods. This processcomprises the step of continuously bringing together, optionally in thepresence of one or more intervening or adjacent materials (as describedin the previous section), at least one insulation material (which can beof any type, but which is preferably substantially hydrophobic) and atleast one high temperature-resistant material. In a preferred embodimentof the process, fibrous insulation material can be continuouslydeposited on a moving web of high temperature-resistant material, forexample, by melt blowing, air laying, or carding.

[0039] Unlike conventional insulation blankets (which rely uponselvedges for blanket assembly and casing), blankets produced by thecontinuous process of the invention can, if desired, be constructed soas to have substantially coextensive layers. The preferred use ofpolymeric insulation material (more preferably, fibrous polymericinsulation material) provides blankets that are cold-sealable bycutting. If desired, the blankets can be provided with check valves,although these are not necessary due to the blankets' casing-freeconstruction. Other optional features include holes (to aid in blanketinstallation) and non-encasing external protective layers.

[0040] The blankets of the invention are useful in a variety ofapplications requiring thermal and/or acoustic insulation (for example,in aircraft, automobiles, and other vehicles) and can be installed usingknown methods. The blankets can be particularly useful as fire barriers.

EXAMPLES

[0041] Objects and advantages of this invention are further illustratedby the following examples, but the particular materials and amountsthereof recited in these examples, as well as other conditions anddetails, should not be construed to unduly limit this invention.

[0042] Flammability Requirements of the Federal Aviation Administration

[0043] 14 C.F.R. Section 25.853 Compartment Interiors.

[0044] For each compartment occupied by the crew or passengers, thefollowing apply:

[0045] (a) Materials (including finishes or decorative surfaces appliedto the materials) must meet the applicable test criteria prescribed inpart I of appendix F of this part, or other approved equivalent methods,regardless of the passenger capacity of the airplane.

[0046] (b) [Reserved]

[0047] (c) In addition to meeting the requirements of paragraph (a) ofthis section, seat cushions, except those on flight crewmember seats,must meet the test requirements of part II of appendix F of this part,or other equivalent methods, regardless of the passenger capacity of theairplane.

[0048] (d) Except as provided in paragraph (e) of this section, thefollowing interior components of airplanes with passenger capacities of20 or more must also meet the test requirements of parts IV and V ofappendix F of this part, or other approved equivalent method, inaddition to the flammability requirements prescribed in paragraph (a) ofthis section:

[0049] (1) Interior ceiling and wall panels, other than lighting lensesand windows;

[0050] (2) Partitions, other than transparent panels needed to enhancecabin safety;

[0051] (3) Galley structure, including exposed surfaces of stowed cartsand standard containers and the cavity walls that are exposed when afull complement of such carts or containers is not carried; and

[0052] (4) Large cabinets and cabin stowage compartments, other thanunderseat stowage compartments for stowing small items such as magazinesand maps.

[0053] (e) The interiors of compartments, such as pilot compartments,galleys, lavatories, crew rest quarters, cabinets and stowagecompartments, need not meet the standards of paragraph (d) of thissection, provided the interiors of such compartments are isolated fromthe main passenger cabin by doors or equivalent means that wouldnormally be closed during an emergency landing condition.

[0054] (f) Smoking is not to be allowed in lavatories. If smoking is tobe allowed in any other compartment occupied by the crew or passengers,an adequate number of self-contained, removable ashtrays must beprovided for all seated occupants.

[0055] (g) Regardless of whether smoking is allowed in any other part ofthe airplane, lavatories must have self-contained, removable ashtrayslocated conspicuously on or near the entry side of each lavatory door,except that one ashtray may serve more than one lavatory door if theashtray can be seen readily from the cabin side of each lavatory served.

[0056] (h) Each receptacle used for the disposal of flammable wastematerial must be fully enclosed, constructed of at least fire resistantmaterials, and must contain fires likely to occur in it under normaluse. The capability of the receptacle to contain those fires under allprobable conditions of wear, misalignment, and ventilation expected inservice must be demonstrated by test.

[0057] [Arndt. 25-83, 60 FR 6623, Feb. 2, 1995]

[0058] 14 C.F.R. Section 25.855 Cargo or Baggage Compartments

[0059] For each cargo and baggage compartment not occupied by crew orpassengers, the following apply:

[0060] (a) The compartment must meet one of the class requirements of§25.857.

[0061] (b) Class B through Class E cargo or baggage compartments, asdefined in §25.857, must have a liner, and the liner must be separatefrom (but may be attached to) the airplane structure.

[0062] (c) Ceiling and sidewall liner panels of Class C compartmentsmust meet the test requirements of part III of appendix F of this partor other approved equivalent methods.

[0063] (d) All other materials used in the construction of the cargo orbaggage compartment must meet the applicable test criteria prescribed inpart I of appendix F of this part or other approved equivalent methods.

[0064] (e) No compartment may contain any controls, wiring, lines,equipment, or accessories whose damage or failure would affect safeoperation, unless those items are protected so that—

[0065] (1) They cannot be damaged by the movement of cargo in thecompartment, and

[0066] (2) Their breakage or failure will not create a fire hazard.

[0067] (f) There must be means to prevent cargo or baggage frominterfering with the functioning of the fire protective features of thecompartment.

[0068] (g) Sources of heat within the compartment must be shielded andinsulated to prevent igniting the cargo or baggage.

[0069] (h) Flight tests must be conducted to show compliance with theprovisions of §25.857 concerning—

[0070] (1) Compartment accessibility,

[0071] (2) The entries of hazardous quantities of smoke or extinguishingagent into compartments occupied by the crew or passengers, and

[0072] (3) The dissipation of the extinguishing agent in Class Ccompartments.

[0073] (i) During the above tests, it must be shown that no inadvertentoperation of smoke or fire detectors in any compartment would occur as aresult of fire contained in any other compartment, either during orafter extinguishment, unless the extinguishing system floods each suchcompartment simultaneously.

[0074] [Amdt. 25-72, 55 FR 29784, Jul. 20, 1990, as amended by Amdt.25-93, 63 FR 8048, Feb.17, 1998

[0075] 14 C.F.R. Section 25.856 Thermal/Acoustic Insulation Materials.

[0076] (a) Thermal/acoustic insulation material installed in thefuselage must meet the flame propagation test requirements of part VI ofAppendix F to this part, or other approved equivalent test requirements.This requirement does not apply to “small parts,” as defined in part Iof Appendix F of this part.

[0077] (b) For airplanes with a passenger capacity of 20 or greater,thermal/acoustic insulation materials (including the means of fasteningthe materials to the fuselage) installed in the lower half of theairplane fuselage must meet the flame penetration resistance testrequirements of part VII of Appendix F to this part, or other approvedequivalent test requirements. This requirement does not apply tothermal/acoustic insulation installations that the FAA finds would notcontribute to fire penetration resistance.

[0078] [Amdt. 25-111, 68 FR 45059, Jul. 31, 2003]

[0079] Appendix F to Part 25

[0080] Part I—Test Criteria and Procedures for Showing Compliance withSection 25.853 or Section 25.855.

[0081] (a) Material test criteria—(1) Interior compartments occupied bycrew or passengers. (i) Interior ceiling panels, interior wall panels,partitions, galley structure, large cabinet walls, structural flooring,and materials used in the construction of stowage compartments (otherthan underseat stowage compartments and compartments for stowing smallitems such as magazines and maps) must be self-extinguishing when testedvertically in accordance with the applicable portions of part I of thisappendix. The average burn length may not exceed 6 inches and theaverage flame time after removal of the flame source may not exceed 15seconds. Drippings from the test specimen may not continue to flame formore than an average of 3 seconds after falling.

[0082] (ii) Floor covering, textiles (including draperies andupholstery), seat cushions, padding, decorative and nondecorative coatedfabrics, leather, trays and galley furnishings, electrical conduit, airducting, joint and edge covering, liners of Class B and E cargo orbaggage compartments, floor panels of Class B, C, D, or E cargo orbaggage compartments, cargo covers and transparencies, molded andthermoformed parts, air ducting joints, and trim strips (decorative andchafing), that are constructed of materials not covered in subparagraph(iv) below, must be self-extinguishing when tested vertically inaccordance with the applicable portions of part I of this appendix orother approved equivalent means. The average burn length may not exceed8 inches, and the average flame time after removal of the flame sourcemay not exceed 15 seconds. Drippings from the test specimen may notcontinue to flame for more than an average of 5 seconds after falling.

[0083] (iii) Motion picture film must be safety film meeting theStandard Specifications for Safety Photographic Film PHI.25 (availablefrom the American National Standards Institute, 1430 Broadway, New York,N.Y. 10018). If the film travels through ducts, the ducts must meet therequirements of subparagraph (ii) of this paragraph.

[0084] (iv) Clear plastic windows and signs, parts constructed in wholeor in part of elastomeric materials, edge lighted instrument assembliesconsisting of two or more instruments in a common housing, seat belts,shoulder harnesses, and cargo and baggage tiedown equipment, includingcontainers, bins, pallets, etc., used in passenger or crew compartments,may not have an average burn rate greater than 2.5 inches per minutewhen tested horizontally in accordance with the applicable portions ofthis appendix.

[0085] (v) Except for small parts (such as knobs, handles, rollers,fasteners, clips, grommets, rub strips, pulleys, and small electricalparts) that would not contribute significantly to the propagation of afire and for electrical wire and cable insulation, materials in itemsnot specified in paragraphs (a)(1)(i), (ii), (iii), or (iv) of part I ofthis appendix may not have a burn rate greater than 4.0 inches perminute when tested horizontally in accordance with the applicableportions of this appendix.

[0086] (2) Cargo and baggage compartments not occupied by crew orpassengers.

[0087] (i) [Reserved]

[0088] (ii) A cargo or baggage compartment defined in §25.857 as Class Bor E must have a liner constructed of materials that meet therequirements of paragraph (a)(1)(ii) of part I of this appendix andseparated from the airplane structure (except for attachments). Inaddition, such liners must be subjected to the 45 degree angle test. Theflame may not penetrate (pass through) the material during applicationof the flame or subsequent to its removal. The average flame time afterremoval of the flame source may not exceed 15 seconds, and the averageglow time may not exceed 10 seconds.

[0089] (iii) A cargo or baggage compartment defined in §25.857 as ClassB, C, D, or E must have floor panels constructed of materials which meetthe requirements of paragraph (a)(1)(ii) of part I of this appendix andwhich are separated from the airplane structure (except forattachments). Such panels must be subjected to the 45 degree angle test.The flame may not penetrate (pass through) the material duringapplication of the flame or subsequent to its removal. The average flametime after removal of the flame source may not exceed 15 seconds, andthe average glow time may not exceed 10 seconds.

[0090] (iv) Insulation blankets and covers used to protect cargo must beconstructed of materials that meet the requirements of paragraph(a)(1)(ii) of part I of this appendix. Tiedown equipment (includingcontainers, bins, and pallets) used in each cargo and baggagecompartment must be constructed of materials that meet the requirementsof paragraph (a)(1)(v) of part I of this appendix.

[0091] (3) Electrical system components. Insulation on electrical wireor cable installed in any area of the fuselage must beself-extinguishing when subjected to the 60 degree test specified inpart I of this appendix. The average burn length may not exceed 3inches, and the average flame time after removal of the flame source maynot exceed 30 seconds. Drippings from the test specimen may not continueto flame for more than an average of 3 seconds after falling.

[0092] (b) Test Procedures—(1) Conditioning. Specimens must beconditioned to 70±5 F., and at 50 percent ±5 percent relative humidityuntil moisture equilibrium is reached or for 24 hours. Each specimenmust remain in the conditioning environment until it is subjected to theflame.

[0093] (2) Specimen configuration. Except for small parts and electricalwire and cable insulation, materials must be tested either as sectioncut from a fabricated part as installed in the airplane or as a specimensimulating a cut section, such as a specimen cut from a flat sheet ofthe material or a model of the fabricated part. The specimen may be cutfrom any location in a fabricated part; however, fabricated units, suchas sandwich panels, may not be separated for test. Except as notedbelow, the specimen thickness must be no thicker than the minimumthickness to be qualified for use in the airplane. Test specimens ofthick foam parts, such as seat cushions, must be ½-inch in thickness.Test specimens of materials that must meet the requirements of paragraph(a)(1)(v) of part I of this appendix must be no more than ⅛-inch inthickness. Electrical wire and cable specimens must be the same size asused in the airplane. In the case of fabrics, both the warp and filldirection of the weave must be tested to determine the most criticalflammability condition. Specimens must be mounted in a metal frame sothat the two long edges and the upper edge are held securely during thevertical test prescribed in subparagraph (4) of this paragraph and thetwo long edges and the edge away from the flame are held securely duringthe horizontal test prescribed in subparagraph (5) of this paragraph.The exposed area of the specimen must be at least 2 inches wide and 12inches long, unless the actual size used in the airplane is smaller. Theedge to which the burner flame is applied must not consist of thefinished or protected edge of the specimen but must be representative ofthe actual cross-section of the material or part as installed in theairplane. The specimen must be mounted in a metal frame so that all fouredges are held securely and the exposed area of the specimen is at least8 inches by 8 inches during the 45° test prescribed in subparagraph (6)of this paragraph.

[0094] (3) Apparatus. Except as provided in subparagraph (7) of thisparagraph, tests must be conducted in a draft-free cabinet in accordancewith Federal Test Method Standard 191 Model 5903 (revised Method 5902)for the vertical test, or Method 5906 for horizontal test (availablefrom the General Services Administration, Business Service Center,Region 3, Seventh & D Streets SW., Washington, DC 20407). Specimenswhich are too large for the cabinet must be tested in similar draft-freeconditions.

[0095] (4) Vertical test. A minimum of three specimens must be testedand results averaged. For fabrics, the direction of weave correspondingto the most critical flammability conditions must be parallel to thelongest dimension. Each specimen must be supported vertically. Thespecimen must be exposed to a Bunsen or Tirrill burner with a nominal⅜-inch I.D. tube adjusted to give a flame of 1½ inches in height. Theminimum flame temperature measured by a calibrated thermocouplepyrometer in the center of the flame must be 1550° F. The lower edge ofthe specimen must be ¾-inch above the top edge of the burner. The flamemust be applied to the center line of the lower edge of the specimen.For materials covered by paragraph (a)(1)(i) of part I of this appendix,the flame must be applied for 60 seconds and then removed. For materialscovered by paragraph (a)(1)(ii) of part I of this appendix, the flamemust be applied for 12 seconds and then removed. Flame time, burnlength, and flaming time of drippings, if any, may be recorded. The burnlength determined in accordance with subparagraph (7) of this paragraphmust be measured to the nearest tenth of an inch.

[0096] (5) Horizontal test. A minimum of three specimens must be testedand the results averaged. Each specimen must be supported horizontally.The exposed surface, when installed in the aircraft, must be face downfor the test. The specimen must be exposed to a Bunsen or Tirrill burnerwith a nominal ⅜-inch I.D. tube adjusted to give a flame of 1½ inches inheight. The minimum flame temperature measured by a calibratedthermocouple pyrometer in the center of the flame must be 1550° F. Thespecimen must be positioned so that the edge being tested is centered¾-inch above the top of the burner. The flame must be applied for 15seconds and then removed. A minimum of 10 inches of specimen must beused for timing purposes, approximately 1½ inches must burn before theburning front reaches the timing zone, and the average burn rate must berecorded.

[0097] (6) Forty-five degree test. A minimum of three specimens must betested and the results averaged. The specimens must be supported at anangle of 45° to a horizontal surface. The exposed surface when installedin the aircraft must be face down for the test. The specimens must beexposed to a Bunsen or Tirrill burner with a nominal ⅜-inch I.D. tubeadjusted to give a flame of 1½ inches in height. The minimum flametemperature measured by a calibrated thermocouple pyrometer in thecenter of the flame must be 1550° F. Suitable precautions must be takento avoid drafts. The flame must be applied for 30 seconds with one-thirdcontacting the material at the center of the specimen and then removed.Flame time, glow time, and whether the flame penetrates (passes through)the specimen must be recorded.

[0098] (7) Sixty degree test. A minimum of three specimens of each wirespecification (make and size) must be tested. The specimen of wire orcable (including insulation) must be placed at an angle of 60° with thehorizontal in the cabinet specified in subparagraph (3) of thisparagraph with the cabinet door open during the test, or must be placedwithin a chamber approximately 2 feet high by 1 foot by 1 foot, open atthe top and at one vertical side (front), and which allows sufficientflow of air for complete combustion, but which is free from drafts. Thespecimen must be parallel to and approximately 6 inches from the frontof the chamber. The lower end of the specimen must be held rigidlyclamped. The upper end of the specimen must pass over a pulley or rodand must have an appropriate weight attached to it so that the specimenis held tautly throughout the flammability test. The test specimen spanbetween lower clamp and upper pulley or rod must be 24 inches and mustbe marked 8 inches from the lower end to indicate the central point forflame application. A flame from a Bunsen or Tirrill burner must beapplied for 30 seconds at the test mark. The burner must be mountedunderneath the test mark on the specimen, perpendicular to the specimenand at an angle of 30° to the vertical plane of the specimen. The burnermust have a nominal bore of ⅜-inch and be adjusted to provide a 3-inchhigh flame with an inner cone approximately one-third of the flameheight. The minimum temperature of the hottest portion of the flame, asmeasured with a calibrated thermocouple pyrometer, may not be less than1750° F. The burner must be positioned so that the hottest portion ofthe flame is applied to the test mark on the wire. Flame time, burnlength, and flaming time of drippings, if any, must be recorded. Theburn length determined in accordance with paragraph (8) of thisparagraph must be measured to the nearest tenth of an inch. Breaking ofthe wire specimens is not considered a failure.

[0099] (8) Burn length. Burn length is the distance from the originaledge to the farthest evidence of damage to the test specimen due toflame impingement, including areas of partial or complete consumption,charring, or embrittlement, but not including areas sooted, stained,warped, or discolored, nor areas where material has shrunk or meltedaway from the heat source.

[0100] Part VI—Test Method to Determine the Flammability and FlamePropagation Characteristics of Thermal/Acoustic Insulation Materials

[0101] Use this test method to evaluate the flammability and flamepropagation characteristics of thermal/acoustic insulation when exposedto both a radiant heat source and a flame.

[0102] (a) Definitions.

[0103] “Flame propagation” means the furthest distance of thepropagation of visible flame towards the far end of the test specimen,measured from the midpoint of the ignition source flame. Measure thisdistance after initially applying the ignition source and before allflame on the test specimen is extinguished. The measurement is not adetermination of burn length made after the test.

[0104] “Radiant heat source” means an electric or air propane panel.

[0105] “Thermal/acoustic insulation” means a material or system ofmaterials used to provide thermal and/or acoustic protection. Examplesinclude fiberglass or other batting material encapsulated by a filmcovering and foams.

[0106] “Zero point” means the point of application of the pilot burnerto the test specimen.

[0107] (b) Test Apparatus.

[0108] (1) Radiant panel test chamber. Conduct tests in a radiant paneltest chamber. Place the test chamber under an exhaust hood to facilitateclearing the chamber of smoke after each test. The radiant panel testchamber must be an enclosure 55 inches (1397 mm) long by 19.5 (495 mm)deep by 28 (710 mm) to 30 inches (maximum) (762 mm) above the testspecimen. Insulate the sides, ends, and top with a fibrous ceramicinsulation, such as Kaowool M™ board. On the front side, provide a 52 by12-inch (1321 by 305 mm) draft-free, high-temperature, glass window forviewing the sample during testing. Place a door below the window toprovide access to the movable specimen platform holder. The bottom ofthe test chamber must be a sliding steel platform that has provision forsecuring the test specimen holder in a fixed and level position. Thechamber must have an internal chimney with exterior dimensions of 5.1inches (129 mm) wide, by 16.2 inches (411 mm) deep by 13 inches (330 mm)high at the opposite end of the chamber from the radiant energy source.The interior dimensions must be 4.5 inches (114 mm) wide by 15.6 inches(395 mm) deep. The chimney must extend to the top of the chamber.

[0109] (2) Radiant heat source. Mount the radiant heat energy source ina cast iron frame or equivalent. An electric panel must have six, 3-inchwide emitter strips. The emitter strips must be perpendicular to thelength of the panel. The panel must have a radiation surface of 12⅞ by18½ inches (327 by 470 mm). The panel must be capable of operating attemperatures up to 1300° F. (704° C.). An air propane panel must be madeof a porous refractory material and have a radiation surface of 12 by 18inches (305 by 457 mm). The panel must be capable of operating attemperatures up to 1,500° F. (816° C.).

[0110] i) Electric radiant panel. The radiant panel must be 3-phase andoperate at 208 volts. A single-phase, 240 volt panel is also acceptable.Use a solid-state power controller and microprocessor-based controllerto set the electric panel operating parameters.

[0111] (ii) Gas radiant panel. Use propane (liquid petroleum gas—2.1 UN1075) for the radiant panel fuel. The panel fuel system must consist ofa venturi-type aspirator for mixing gas and air at approximatelyatmospheric pressure. Provide suitable instrumentation for monitoringand controlling the flow of fuel and air to the panel. Include an airflow gauge, an air flow regulator, and a gas pressure gauge.

[0112] (iii) Radiant panel placement. Mount the panel in the chamber at30° to the horizontal specimen plane, and 7½ inches above the zero pointof the specimen.

[0113] (3) Specimen holding system.

[0114] (i) The sliding platform serves as the housing for test specimenplacement. Brackets may be attached (via wing nuts) to the top lip ofthe platform in order to accommodate various thicknesses of testspecimens. Place the test specimens on a sheet of Kaowool M™ board or1260 Standard Board (manufactured by Thermal Ceramics and available inEurope), or equivalent, either resting on the bottom lip of the slidingplatform or on the base of the brackets. It may be necessary to usemultiple sheets of material based on the thickness of the test specimen(to meet the sample height requirement). Typically, thesenon-combustible sheets of material are available in ¼ inch (6 mm)thicknesses. A sliding platform that is deeper than a 2-inch (50.8 mm)platform is acceptable as long as the sample height requirement is met.

[0115] (ii) Attach a ½ inch (13 mm) piece of Kaowool M™ board or otherhigh temperature material measuring 41½ by 8¼ inches (1054 by 210 mm) tothe back of the platform. This board serves as a heat retainer andprotects the test specimen from excessive preheating. The height of thisboard must not impede the sliding platform movement (in and out of thetest chamber). If the platform has been fabricated such that the backside of the platform is high enough to prevent excess preheating of thespecimen when the sliding platform is out, a retainer board is notnecessary.

[0116] (iii) Place the test specimen horizontally on the non-combustibleboard(s). Place a steel retaining/securing frame fabricated of mildsteel, having a thickness of ⅛ inch (3.2 mm) and overall dimensions of23 by 13⅛ inches (584 by 333 mm) with a specimen opening of 19 by 10¾inches (483 by 273 mm) over the test specimen. The front, back, andright portions of the top flange of the frame must rest on the top ofthe sliding platform, and the bottom flanges must pinch all 4 sides ofthe test specimen. The right bottom flange must be flush with thesliding platform.

[0117] (4) Pilot Burner. The pilot burner used to ignite the specimenmust be a Bernzomatic™ commercial propane venturi torch with an axiallysymmetric burner tip and a propane supply tube with an orifice diameterof 0.006 inches (0.15 mm). The length of the burner tube must be 2⅞inches (71 mm). The propane flow must be adjusted via gas pressurethrough an in-line regulator to produce a blue inner cone length of ¾inch (19 mm). A ¾ inch (19 mm) guide (such as a thin strip of metal) maybe soldered to the top of the burner to aid in setting the flame height.The overall flame length must be approximately 5 inches long (127 mm).Provide a way to move the burner out of the ignition position so thatthe flame is horizontal and at least 2 inches (50 mm) above the specimenplane.

[0118] (5) Thermocouples. Install a 24 American Wire Gauge (AWG) Type K(Chromel-Alumel) thermocouple in the test chamber for temperaturemonitoring. Insert it into the chamber through a small hole drilledthrough the back of the chamber. Place the thermocouple so that itextends 11 inches (279 mm) out from the back of the chamber wall, 11½inches (292 mm) from the right side of the chamber wall, and is 2 inches(51 mm) below the radiant panel. The use of other thermocouples isoptional.

[0119] (6) Calorimeter. The calorimeter must be a one-inch cylindricalwater-cooled, total heat flux density, foil type Gardon Gage that has arange of 0 to 5 BTU/ft²-second (0 to 5.7 Watts/cm²).

[0120] (7) Calorimeter calibration specification and procedure.

[0121] (i) Calorimeter specification.

[0122] (A) Foil diameter must be 0.25±0.005 inches (6.35±0.13 mm).

[0123] (B) Foil thickness must be 0.0005±0.0001 inches (0.013±0.0025mm).

[0124] (C) Foil material must be thermocouple grade Constantan.

[0125] (D) Temperature measurement must be a Copper Constantanthermocouple.

[0126] (E) The copper center wire diameter must be 0.0005 inches (0.013mm).

[0127] (F) The entire face of the calorimeter must be lightly coatedwith “Black Velvet” paint having an emissivity of 96 or greater.

[0128] (ii) Calorimeter calibration.

[0129] (A) The calibration method must be by comparison to a likestandardized transducer.

[0130] (B) The standardized transducer must meet the specificationsgiven in paragraph VI(b)(6) of this appendix.

[0131] (C) Calibrate the standard transducer against a primary standardtraceable to the National Institute of Standards and Technology (NIST).

[0132] (D) The method of transfer must be a heated graphite plate.

[0133] (E) The graphite plate must be electrically heated, have a clearsurface area on each side of the plate of at least 2 by 2 inches (51 by51 mm), and be ⅛ inch ±{fraction (1/16)} inch thick (3.2±1.6 mm).

[0134] (F) Center the 2 transducers on opposite sides of the plates atequal distances from the plate.

[0135] (G) The distance of the calorimeter to the plate must be no lessthan 0.0625 inches (1.6 mm), nor greater than 0.375 inches (9.5 mm).

[0136] (H) The range used in calibration must be at least 0-3.5 BTUs/ft²second (0-3.9 Watts/cm² ) and no greater than 0-5.7 BTUs/ft² second(0-6.4 Watts/cm²).

[0137] (I) The recording device used must record the 2 transducerssimultaneously or at least within {fraction (1/10)} of each other.

[0138] (8) Calorimeter fixture. With the sliding platform pulled out ofthe chamber, install the calorimeter holding frame and place a sheet ofnon-combustible material in the bottom of the sliding platform adjacentto the holding frame. This will prevent heat losses during calibration.The frame must be 13⅛ inches (333 mm) deep (front to back) by 8 inches(203 mm) wide and must rest on the top of the sliding platform. It mustbe fabricated of ⅛ inch (3.2 mm) flat stock steel and have an openingthat accommodates a ½ inch (12.7 mm) thick piece of refractory board,which is level with the top of the sliding platform. The board must havethree 1-inch (25.4 mm) diameter holes drilled through the board forcalorimeter insertion. The distance to the radiant panel surface fromthe centerline of the first hole (“zero” position) must be 7½±⅛ inches(191±3 mm). The distance between the centerline of the first hole to thecenterline of the second hole must be 2 inches (51 mm). It must also bethe same distance from the centerline of the second hole to thecenterline of the third hole. A calorimeter holding frame that differsin construction is acceptable as long as the height from the centerlineof the first hole to the radiant panel and the distance between holes isthe same as described in this paragraph.

[0139] (9) Instrumentation. Provide a calibrated recording device withan appropriate range or a computerized data acquisition system tomeasure and record the outputs of the calorimeter and the thermocouple.The data acquisition system must be capable of recording the calorimeteroutput every second during calibration.

[0140] (10) Timing device. Provide a stopwatch or other device, accurateto ±1 second/hour, to measure the time of application of the pilotburner flame.

[0141] (c) Test Specimens.

[0142] (1) Specimen preparation. Prepare and test a minimum of threetest specimens. If an oriented film cover material is used, prepare andtest both the warp and fill directions.

[0143] (2) Construction. Test specimens must include all materials usedin construction of the insulation (including batting, film, scrim, tapeetc.). Cut a piece of core material such as foam or fiberglass, and cuta piece of film cover material (if used) large enough to cover the corematerial. Heat sealing is the preferred method of preparing fiberglasssamples, since they can be made without compressing the fiberglass (“boxsample”). Cover materials that are not heat sealable may be stapled,sewn, or taped as long as the cover material is over-cut enough to bedrawn down the sides without compressing the core material. Thefastening means should be as continuous as possible along the length ofthe seams. The specimen thickness must be of the same thickness asinstalled in the airplane.

[0144] (3) Specimen Dimensions. To facilitate proper placement ofspecimens in the sliding platform housing, cut non-rigid core materials,such as fiberglass, 12½ inches (318mm) wide by 23 inches (584 mm) long.Cut rigid materials, such as foam, 11½±¼ inches (292 mm ±6 mm) wide by23 inches (584 mm) long in order to fit properly in the sliding platformhousing and provide a flat, exposed surface equal to the opening in thehousing.

[0145] (d) Specimen conditioning. Condition the test specimens at 70±5°F. (21±2° C.) and 55% ±10% relative humidity, for a minimum of 24 hoursprior to testing.

[0146] (e) Apparatus Calibration.

[0147] (1) With the sliding platform out of the chamber, install thecalorimeter holding frame. Push the platform back into the chamber andinsert the calorimeter into the first hole (“zero” position). Close thebottom door located below the sliding platform. The distance from thecenterline of the calorimeter to the radiant panel surface at this pointmust be 7.{fraction (1/2)} inches ±⅛ (191 mm ±3). Prior to igniting theradiant panel, ensure that the calorimeter face is clean and that thereis water running through the calorimeter.

[0148] (2) Ignite the panel. Adjust the fuel/air mixture to achieve 1.5BTUs/ft²-second ±5% (1.7 Watts/cm²±5%) at the “zero” position. If usingan electric panel, set the power controller to achieve the proper heatflux. Allow the unit to reach steady state (this may take up to 1 hour).The pilot burner must be off and in the down position during this time.

[0149] (3) After steady-state conditions have been reached, move thecalorimeter 2 inches (51 mm) from the “zero” position (first hole) toposition 1 and record the heat flux. Move the calorimeter to position 2and record the heat flux. Allow enough time at each position for thecalorimeter to stabilize. Table 1 depicts typical calibration values atthe three positions. TABLE 1 Calibration Table Position BTU's/ft² secWatts/cm² “Zero” Position 1.5 1.7 Position 1 1.51-1.50-1.491.71-1.70-1.69 Position 2 1.43-1.44 1.62-1.63

[0150] (4) Open the bottom door, remove the calorimeter and holderfixture. Use caution as the fixture is very hot.

[0151] (f) Test Procedure.

[0152] (1) Ignite the pilot burner. Ensure that it is at least 2 inches(51 mm) above the top of the platform. The burner must not contact thespecimen until the test begins.

[0153] (2) Place the test specimen in the sliding platform holder.Ensure that the test sample surface is level with the top of theplatform. At “zero” point, the specimen surface must be 7½ inches ±⅛inch (191 mm ±3) below the radiant panel.

[0154] (3) Place the retaining/securing frame over the test specimen. Itmay be necessary (due to compression) to adjust the sample (up or down)in order to maintain the distance from the sample to the radiant panel(7½ inches ±⅛ inch (191 mm±3) at “zero” position). With film/fiberglassassemblies, it is critical to make a slit in the film cover to purge anyair inside. This allows the operator to maintain the proper testspecimen position (level with the top of the platform) and to allowventilation of gases during testing. A longitudinal slit, approximately2 inches (51 mm) in length, must be centered 3 inches ±½ inch (76 mm±13mm) from the left flange of the securing frame. A utility knife isacceptable for slitting the film cover.

[0155] (4) Immediately push the sliding platform into the chamber andclose the bottom door.

[0156] (5) Bring the pilot burner flame into contact with the center ofthe specimen at the “zero” point and simultaneously start the timer. Thepilot burner must be at a 27° angle with the sample and be approximately½ inch (12 mm) above the sample. A stop allows the operator to positionthe burner correctly each time.

[0157] (6) Leave the burner in position for 15 seconds and then removeto a position at least 2 inches (51 mm) above the specimen.

[0158] (g) Report.

[0159] (1) Identify and describe the test specimen.

[0160] (2) Report any shrinkage or melting of the test specimen.

[0161] (3) Report the flame propagation distance. If this distance isless than 2 inches, report this as a pass (no measurement required).

[0162] (4) Report the after-flame time.

[0163] (h) Requirements.

[0164] (1) There must be no flame propagation beyond 2 inches (51 mm) tothe left of the centerline of the pilot flame application.

[0165] (2) The flame time after removal of the pilot burner may notexceed 3 seconds on any specimen.

[0166] Part VII—Test Method to Determine the Burnthrough Resistance ofThermal/Acoustic Insulation Materials

[0167] Use the following test method to evaluate the burnthroughresistance characteristics of aircraft thermal/acoustic insulationmaterials when exposed to a high intensity open flame.

[0168] (a) Definitions.

[0169] Burnthrough time means the time, in seconds, for the burner flameto penetrate the test specimen, and/or the time required for the heatflux to reach 2.0 Btu/ft²sec (2.27 W/cm²) on the inboard side, at adistance of 12 inches (30.5 cm) from the front surface of the insulationblanket test frame, whichever is sooner. The burnthrough time ismeasured at the inboard side of each of the insulation blanketspecimens.

[0170] Insulation blanket specimen means one of two specimens positionedin either side of the test rig, at an angle of 30° with respect tovertical.

[0171] Specimen set means two insulation blanket specimens. Bothspecimens must represent the same production insulation blanketconstruction and materials, proportioned to correspond to the specimensize.

[0172] (b) Apparatus.

[0173] (1) The arrangement of the test apparatus must include thecapability of swinging the burner away from the test specimen duringwarm-up.

[0174] (2) Test burner. The test burner must be a modified gun-type suchas the Park Model DPL 3400. Flame characteristics are highly dependenton actual burner setup. Parameters such as fuel pressure, nozzle depth,stator position, and intake airflow must be properly adjusted to achievethe correct flame output.

[0175] (i) Nozzle. A nozzle must maintain the fuel pressure to yield anominal 6.0 gal/hr (0.378 L/min) fuel flow. A Monarch-manufactured 80°PL (hollow cone) nozzle nominally rated at 6.0 gal/hr at 100 lb/in2(0.71 MPa) delivers a proper spray pattern.

[0176] (ii) Fuel Rail. The fuel rail must be adjusted to position thefuel nozzle at a depth of 0.3125 inch (8 mm) from the end plane of theexit stator, which must be mounted in the end of the draft tube.

[0177] (iii) Internal Stator. The internal stator, located in the middleof the draft tube, must be positioned at a depth of 3.75 inches (95 mm)from the tip of the fuel nozzle. The stator must also be positioned suchthat the integral igniters are located at an angle midway between the 10and 11 o'clock position, when viewed looking into the draft tube. Minordeviations to the igniter angle are acceptable if the temperature andheat flux requirements conform to the requirements of paragraph VII(e)of this appendix.

[0178] (iv) Blower Fan. The cylindrical blower fan used to pump airthrough the burner must measure 5.25 inches (133 mm) in diameter by 3.5inches (89 mm) in width.

[0179] (v) Burner cone. Install a 12+0.125-inch (305±3 mm) burnerextension cone at the end of the draft tube. The cone must have anopening 6±0.125-inch (152±3 mm) high and 11±0.125-inch (280±3 mm) wide.

[0180] (vi) Fuel. Use JP-8, Jet A, or their international equivalent, ata flow rate of 6.0±0.2 gal/hr (0.378±0126 L/min). If this fuel isunavailable, ASTM K2 fuel (Number 2 grade kerosene) or ASTM D2 fuel(Number 2 grade fuel oil or Number 2 diesel fuel) are acceptable if thenominal fuel flow rate, temperature, and heat flux measurements conformto the requirements of paragraph VII(e) of this appendix.

[0181] (vii) Fuel pressure regulator. Provide a fuel pressure regulator,adjusted to deliver a nominal 6.0 gal/hr (0.378 L/min) flow rate. Anoperating fuel pressure of 100 lb/in 2 (0.71 MPa) for a nominally rated6.0 gal/hr 80° spray angle nozzle (such as a PL type) delivers 6.0±0.2gal/hr (0.378±0.0126 L/min).

[0182] (3) Calibration Rig and Equipment.

[0183] (i) Construct individual calibration rigs to incorporate acalorimeter and thermocouple rake for the measurement of heat flux andtemperature. Position the calibration rigs to allow movement of theburner from the test rig position to either the heat flux or temperatureposition with minimal difficulty.

[0184] (ii) Calorimeter. The calorimeter must be a total heat flux, foiltype Gardon Gage of an appropriate range such as 0-20 Btu/ft²-sec(0-22.7 W/cm²), accurate to ±3% of the indicated reading. The heat fluxcalibration method must be in accordance with paragraph VI(b)(7) of thisappendix.

[0185] (iii) Calorimeter mounting. Mount the calorimeter in a 6- by12-±125 inch (152- by 305-±3 mm) by 0.75±0.125 inch (19 mm±3 mm) thickinsulating block which is attached to the heat flux calibration rigduring calibration. Monitor the insulating block for deterioration andreplace it when necessary. Adjust the mounting as necessary to ensurethat the calorimeter face is parallel to the exit plane of the testburner cone.

[0186] (iv) Thermocouples. Provide seven ⅛-inch (3.2 mm) ceramic packed,metal sheathed, type K (Chromel-alumel), grounded junction thermocoupleswith a nominal 24 American Wire Gauge (AWG) size conductor forcalibration. Attach the thermocouples to a steel angle bracket to form athermocouple rake for placement in the calibration rig during burnercalibration.

[0187] (v) Air velocity meter. Use a vane-type air velocity meter tocalibrate the velocity of air entering the burner. An Omega EngineeringModel HH30A is satisfactory. Use a suitable adapter to attach themeasuring device to the inlet side of the burner to prevent air fromentering the burner other than through the measuring device, which wouldproduce erroneously low readings. Use a flexible duct, measuring 4inches wide (102 mm) by 20 feet long (6.1 meters), to supply fresh airto the burner intake to prevent damage to the air velocity meter fromingested soot. An optional airbox permanently mounted to the burnerintake area can effectively house the air velocity meter and provide amounting port for the flexible intake duct.

[0188] (4) Test specimen mounting frame. Make the mounting frame for thetest specimens of ⅛-inch (3.2 mm) thick steel, except for the centervertical former, which should be ¼-inch (6.4 mm) thick to minimizewarpage. The specimen mounting frame stringers (horizontal) should bebolted to the test frame formers (vertical) such that the expansion ofthe stringers will not cause the entire structure to warp. Use themounting frame for mounting the two insulation blanket test specimens.

[0189] (5) Backface calorimeters. Mount two total heat flux Gardon typecalorimeters behind the insulation test specimens on the back side(cold) area of the test specimen mounting frame. Position thecalorimeters along the same plane as the burner cone centerline, at adistance of 4 inches (102 mm) from the vertical centerline of the testframe.

[0190] (i) The calorimeters must be a total heat flux, foil type GardonGage of an appropriate range such as 0-5 Btu/ft²-sec (0-5.7 W/cm²),accurate to ±3% of the indicated reading. The heat flux calibrationmethod must comply with paragraph VI(b)(7) of this appendix.

[0191] (6) Instrumentation. Provide a recording potentiometer or othersuitable calibrated instrument with an appropriate range to measure andrecord the outputs of the calorimeter and the thermocouples.

[0192] (7) Timing device. Provide a stopwatch or other device, accurateto ±1%, to measure the time of application of the burner flame andburnthrough time.

[0193] (8) Test chamber. Perform tests in a suitable chamber to reduceor eliminate the possibility of test fluctuation due to air movement.The chamber must have a minimum floor area of 10 by 10 feet (305 by 305cm).

[0194] (i) Ventilation hood. Provide the test chamber with an exhaustsystem capable of removing the products of combustion expelled duringtests.

[0195] (c) Test Specimens.

[0196] (1) Specimen preparation. Prepare a minimum of three specimensets of the same construction and configuration for testing.

[0197] (2) Insulation Blanket Test Specimen.

[0198] (i) For batt-type materials such as fiberglass, the constructed,finished blanket specimen assemblies must be 32 inches wide by 36 incheslong (81.3 by 91.4 cm), exclusive of heat sealed film edges.

[0199] (ii) For rigid and other non-conforming types of insulationmaterials, the finished test specimens must fit into the test rig insuch a manner as to replicate the actual in-service installation.

[0200] (3) Construction. Make each of the specimens tested using theprincipal components (i.e., insulation, fire barrier material if used,and moisture barrier film) and assembly processes (representative seamsand closures).

[0201] (i) Fire barrier material. If the insulation blanket isconstructed with a fire barrier material, place the fire barriermaterial in a manner reflective of the installed arrangement Forexample, if the material will be placed on the outboard side of theinsulation material, inside the moisture film, place it the same way inthe test specimen.

[0202] (ii) Insulation material. Blankets that utilize more than onevariety of insulation (composition, density, etc.) must have specimensets constructed that reflect the insulation combination used. If,however, several blanket types use similar insulation combinations, itis not necessary to test each combination if it is possible to bracketthe various combinations.

[0203] (iii) Moisture barrier film. If a production blanket constructionutilizes more than one type of moisture barrier film, perform separatetests on each combination. For example, if a polyimide film is used inconjunction with an insulation in order to enhance the burnthroughcapabilities, also test the same insulation when used with a polyvinylfluoride film.

[0204] (iv) Installation on testframe. Attach the blanket test specimensto the test frame using 12 steel spring type clamps. Use the clamps tohold the blankets in place in both of the outer vertical formers, aswell as the center vertical former (4 clamps per former). The clampsurfaces should measure 1 inch by 2 inches (25 by 51 mm). Place the topand bottom clamps 6 inches (15.2 cm) from the top and bottom of the testframe, respectively. Place the middle clamps 8 inches (20.3 cm) from thetop and bottom clamps.

[0205] (Note: For blanket materials that cannot be installed inaccordance with the above, the blankets must be installed in a mannerapproved by the FAA.)

[0206] (v) Conditioning. Condition the specimens at 70°≅5° F. (21°±2°C.) and 55%±10% relative humidity for a minimum of 24 hours prior totesting.

[0207] (d) Preparation of Apparatus.

[0208] (1) Level and center the frame assembly to ensure alignment ofthe calorimeter and/or thermocouple rake with the burner cone.

[0209] (2) Turn on the ventilation hood for the test chamber. Do notturn on the burner blower. Measure the airflow of the test chamber usinga vane anemometer or equivalent measuring device. The vertical airvelocity just behind the top of the upper insulation blanket testspecimen must be 100±50 ft/min (0.51±0.25 m/s). The horizontal airvelocity at this point must be less than 50 ft/min (0.25 m/s).

[0210] (3) If a calibrated flow meter is not available, measure the fuelflow rate using a graduated cylinder of appropriate size. Turn on theburner motor/fuel pump, after insuring that the igniter system is turnedoff. Collect the fuel via a plastic or rubber tube into the graduatedcylinder for a 2-minute period. Determine the flow rate in gallons perhour. The fuel flow rate must be 6.0±0.2 gallons per hour (0.378±0.0126L/min).

[0211] (e) Calibration.

[0212] (1) Position the burner in front of the calorimeter so that it iscentered and the vertical plane of the burner cone exit is 4±0.125inches (102±3 mm) from the calorimeter face. Ensure that the horizontalcenterline of the burner cone is offset 1 inch below the horizontalcenterline of the calorimeter. Without disturbing the calorimeterposition, rotate the burner in front of the thermocouple rake, such thatthe middle thermocouple (number 4 of 7) is centered on the burner cone.

[0213] Ensure that the horizontal centerline of the burner cone is alsooffset 1 inch below the horizontal centerline of the thermocouple tips.Re-check measurements by rotating the burner to each position to ensureproper alignment between the cone and the calorimeter and thermocouplerake. (Note: The test burner mounting system must incorporate “detents”that ensure proper centering of the burner cone with respect to both thecalorimeter and the thermocouple rakes, so that rapid positioning of theburner can be achieved during the calibration procedure.)

[0214] (2) Position the air velocity meter in the adapter or airbox,making certain that no gaps exist where air could leak around the airvelocity measuring device. Turn on the blower/motor while ensuring thatthe fuel solenoid and igniters are off. Adjust the air intake velocityto a level of 2150 ft/min, (10.92 m/s) then turn off the blower/motor.(Note: The Omega HH30 air velocity meter measures 2.625 inches indiameter. To calculate the intake airflow, multiply the cross-sectionalarea (0.03758 ft²) by the air velocity (2150 ft/min) to obtain 80.80ft³/min. An air velocity meter other than the HH30 unit can be used,provided the calculated airflow of 80.80 ft³/min (2.29 m³/min) isequivalent.)

[0215] (3) Rotate the burner from the test position to the warm-upposition. Prior to lighting the burner, ensure that the calorimeter faceis clean of soot deposits, and there is water running through thecalorimeter. Examine and clean the burner cone of any evidence ofbuildup of products of combustion, soot, etc. Soot buildup inside theburner cone may affect the flame characteristics and cause calibrationdifficulties. Since the burner cone may distort with time, dimensionsshould be checked periodically.

[0216] (4) While the burner is still rotated to the warm-up position,turn on the blower/motor, igniters and fuel flow, and light the burner.Allow it to warm up for a period of 2 minutes. Move the burner into thecalibration position and allow 1 minute for calorimeter stabilization,then record the heat flux once every second for a period of 30 seconds.Turn off burner, rotate out of position, and allow to cool. Calculatethe average heat flux over this 30-second duration. The average heatflux should be 16.0±0.8 Btu/ft² sec (18.2±0.9 W/cm²).

[0217] (5) Position the burner in front of the thermocouple rake. Afterchecking for proper alignment, rotate the burner to the warm-upposition, turn on the blower/motor, igniters and fuel flow, and lightthe burner. Allow it to warm up for a period of 2 minutes. Move theburner into the calibration position and allow 1 minute for thermocouplestabilization, then record the temperature of each of the 7thermocouples once every second for a period of 30 seconds. Turn offburner, rotate out of position, and allow to cool. Calculate the averagetemperature of each thermocouple over this 30-second period and record.The average temperature of each of the 7 thermocouples should be 1900°F.±100° F. (1038±56° C.).

[0218] (6) If either the heat flux or the temperatures are not withinthe specified range, adjust the burner intake air velocity and repeatthe procedures of paragraphs (4) and (5) above to obtain the propervalues. Ensure that the inlet air velocity is within the range of 2150ft/min ±50 ft/min (10.92±0.25 m/s).

[0219] (7) Calibrate prior to each test until consistency has beendemonstrated. After consistency has been confirmed, several tests may beconducted with calibration conducted before and after a series of tests.

[0220] (f) Test Procedure.

[0221] (1) Secure the two insulation blanket test specimens to the testframe. The insulation blankets should be attached to the test rig centervertical former using four spring clamps positioned according to thecriteria of paragraph (c)(4) or (c)(4)(i) of this part of this appendix.

[0222] (2) Ensure that the vertical plane of the burner cone is at adistance of 4±0.125 inch (102±3 mm) from the outer surface of thehorizontal stringers of the test specimen frame, and that the burner andtest frame are both situated at a 30° angle with respect to vertical.

[0223] (3) When ready to begin the test, direct the burner away from thetest position to the warm-up position so that the flame will not impingeon the specimens prematurely. Turn on and light the burner and allow itto stabilize for 2 minutes.

[0224] (4) To begin the test, rotate the burner into the test positionand simultaneously start the timing device.

[0225] (5) Expose the test specimens to the burner flame for 4 minutesand then turn off the burner. Immediately rotate the burner out of thetest position.

[0226] (6) Determine (where applicable) the burnthrough time, or thepoint at which the heat flux exceeds 2.0 Btu/ft²-sec (2.27 W/cm²).

[0227] (g) Report.

[0228] (1) Identify and describe the specimen being tested.

[0229] (2) Report the number of insulation blanket specimens tested.

[0230] (3) Report the burnthrough time (if any), and the maximum heatflux on the back face of the insulation blanket test specimen, and thetime at which the maximum occurred.

[0231] (h) Requirements.

[0232] (1) Each of the two insulation blanket test specimens must notallow fire or flame penetration in less than 4 minutes.

[0233] (2) Each of the two insulation blanket test specimens must notallow more than 2.0 Btu/ft²-sec (2.27 W/cm²) on the cold side of theinsulation specimens at a point 12 inches (30.5 cm) from the face of thetest rig.

[0234] [Amdt. 25-32, 37 FR 3972, Feb. 24, 1972]

Test Methods Utilized

[0235] Hydrophobicity

[0236] The ability of a substrate to be wetted was evaluated usingmixtures of water and isopropyl alcohol (IPA). The following testsolutions of IPA in water were first prepared: 16%, 18%, 20%, 22%, 24%and 26% (all percentages were by volume). Each substrate to be evaluatedwas dried for one hour at 60° C. in an air circulating oven and thenallowed to cool to room temperature before testing. Circles measuringabout 1 inch (2.54 cm) were then drawn on a surface of the substrate.Next, about 0.5 mL of the 18% IPA solution was placed inside a firstcircle using a disposable transfer pipette. The IPA solution was thenobserved to determine whether or not it wetted out/into the substrate.If it did wet out, it was graded as a “+”, and, if it did not, it wasgraded as a “−”. This procedure was repeated using the other IPAsolutions and circles. In all cases reported herein, it was evident whenthe solutions wetted the substrate and when they did not. In thismanner, a crossover point was determined at which the EPA solutionwetted out/into the substrate.

[0237] Using this test procedure, the hydrophobicity of melt-blownfibrous web insulation materials containing 55-100 percent by weightpolypropylene (primarily isotactic) and 0-45 percent by weightpolyethylene terephthalate (PET) was evaluated. The results are reportedin Table 1 below. The experiments were repeated several times, usingboth embossed and un-embossed webs, with similar results. The fibrousweb materials used as Samples 1-3 are available from 3M Company, St.Paul, Minn. The 100 percent polypropylene web was prepared using apolypropylene feedstock having a melt flow index of 350 grams/10 minutes(available as FINA 350 from ATO FINA, Deer Park, Tex.) using amelt-blowing process to provide individual fibers having an effectivediameter of less than 12 micrometers (μm), which formed a web having athickness of approximately 1.0-1.5 centimeters (cm) and an areal weightof approximately 200 grams/meter². Polypropylene:Polyester SampleInsulation Material (w:w) 1 3M ™ THINSULATE ™ 55:45 ACOUSTIC INSULATIONTC-3302-60 2 3M ™ THINSULATE ™ 65:35 ACOUSTIC INSULATION AU-2020-1 33M ™ THINSULATE ™ 80:20 ACOUSTIC INSULATION 2099 4 Melt-blownPolypropylene Web 100:0 

[0238] TABLE 1 % Isopropyl Alcohol in Water Sample % Polypropylene 18 2022 24 26 1 55 − + + + + 2 65 − − + + + 3 80 − − − + + 4 100 − − − − +

[0239] A sample of a non-woven web comprising polyethylene-coatedpoly(ethylene terephthalate) staple fibers was also tested using asolution of 16 percent IPA in water, and wetting was observed.

[0240] For reference, the surface tension (gamma) value at 20° C. forlinear polyethylene (infinite molecular weight) is reported as 36.8,that of polypropylene (atactic, MWn=3000) as 28.3, and that ofpoly(ethylene terephthalate) (hereinafter, “PET”, MWn=25,000) as 44.6 byJ. Bicerano in Prediction of Polymer Properties, pp. 195-196, MarcelDekker, Inc., New York (1996). In the Polymer Handbook, J. Brandup, E.Immergut, and E. Grulke (Ed.), 4^(th) Edition, pp. 524 and 530, JohnWiley & Sons, Inc., New York, these values are reported as 36.8(infinite molecular weight), 29.4 (atactic, no MW given), and 44.6(MWn=25,000), respectively, along with values of 29.4 for isotacticpolypropylene (no MW given) and 30.1 for a mixture of isotactic andatactic polypropylene.

[0241] Radiant Panel Test and Burnthrough Test

[0242] Radiant panel testing and burnthrough testing were carried outaccording to the above-detailed Federal Aviation Administrationregulations and procedures in essentially the same manner as thatdescribed at columns 18-24 of U.S. Pat. No. 6,670,291 (Tompkins et al.),the descriptions of which are incorporated herein by reference.

Examples 1-4

[0243] In these examples, various thermal acoustic insulation blanketswere prepared in rollstock form using a continuous process. Theresulting blankets comprised materials in the form of layers that weresubstantially coextensive.

Example 1

[0244] 3M™ NEXTEL™ Flame Stopping Dot Paper (an alumina fiber-basedpaper fire barrier material having a basis weight of 70-80 grams/meter²,available from 3M Company, St. Paul, Minn.) was used to preparerollstock of a two-layer thermal acoustic insulation blanket. The 3M™NEXTEL™ Flame Stopping Dot Paper was fed through a melt-blown processchamber essentially as described at column 8, line 49, to column 10,line 18, of U.S. Pat. No. 5,841,081 (Thompson et al.) to collect anon-woven, melt-blown blend of polypropylene/PET (65:35/w:w) fibers onone side of the fire barrier material. The resulting thermal acousticinsulation blanket in rollstock form comprised a fibrous web (having athickness of approximately 1 inch (2.5 cm) and an areal weight ofapproximately 123 grams/meter²) on a paper fire barrier.

Example 2

[0245] Example 1 was repeated with the following modification: 3M™NEXTEL™ Flame Stopping Coated Paper (a vermiculite coated, aluminafiber-based paper fire barrier material having a basis weight of 70-80grams/meter², available from 3M Company, St. Paul, Minn.) was usedinstead of 3M™ NEXTEL™ Flame Stopping Dot Paper. The resulting thermalacoustic insulation blanket in rollstock form comprised a fibrous web(having a thickness of approximately 1 inch (2.5 cm) and an areal weightof approximately 123 grams/meter²) on a paper fire barrier.

Example 3

[0246] INSULFAB 331 (a lightweight, high strength vapor barriercomprising a scrim-reinforced, metallized polyvinyl fluoride film(available as TEDLAR from E. I. DuPont de Nemours Company, Wilmington,Del.) available from Chase Facile, Incorporated, Paterson, N.J.) wasused to prepare a three-layer thermal acoustic insulation blanket in arollstock form. One piece of INSULFAB 331A was laminated to 3M™ NEXTEL™Flame Stopping Coated Paper. This intermediate two-layer laminate wasfed through a melt-blown process chamber essentially as described inExample 1 to collect a non-woven, melt-blown blend of polypropylene/PET(65:35/w:w) fibers such that the non-woven melt-blown fibers contactedthe fire barrier side of the laminate. A thermal acoustic insulationblanket comprising a paper fire barrier with a vapor barrier laminatedto one side and a fibrous web (having a thickness of approximately 1inch (2.5 cm) and an areal weight of approximately 123 grams/meter²) onthe opposite side was obtained in rollstock form.

Example 4

[0247] Example 3 was repeated with the following modification: a lightcoat of adhesive (3M™ SUPER SPRAY 77 ADHESIVE, available from 3MCompany, St. Paul, Minn.) was applied to the ceramic paper side of theintermediate fire barrier/vapor barrier laminate prior to feeding itthrough the melt-blown process chamber. A thermal acoustic insulationblanket comprising a paper fire barrier with a vapor barrier laminatedto one side and a fibrous web (having a thickness of approximately 2inches (5.0 cm) and an areal weight of approximately 121 grams/meter²)adhered to the opposite side was obtained in rollstock form.

Examples 5-7

[0248] In these examples, various thermal acoustic insulation blanketswere prepared using manual lay-up methods and were evaluated usingradiant panel and burnthrough tests.

Example 5

[0249] Two pieces of INSULFAB 2000A (a lightweight, high strength vaporbarrier comprising a scrim-reinforced polyimide film, available fromChase Facile, Incorporated, Paterson, N.J.) were used to prepare afour-layer thermal acoustic insulation blanket. More specifically, twopieces of INSULFAB 2000A were used to encapsulate one piece each of 1)3M™ NEXTEL™ Flame Stopping Dot Paper (fire barrier) and 2) a web formedfrom a non-woven, melt-blown blend of polypropylene/PET (65:35/w:w)fibers and having a thickness of approximately 1 inch (2.5 cm) and anareal weight of approximately 417 grams/meter² (commercially availableas 3M™ THINSULATE™ ACOUSTIC INSULATION AU 4020-6 from 3M Company, St.Paul, Minn.) such that the adhesive side of the INSULFAB 2000A sheetscontacted the fire barrier and the non-woven web. The pieces were laidup so as to provide an overhanging edge of the INSULFAB 2000A layersaround the outer border of the fire barrier and non-woven web pieces.The facing adhesive edges of the two INSULFAB 2000A layers were heatsealed together using a tool having a temperature of between 300 and320° F. (149 and 160° C.) to produce a final thermal acoustic insulationsample.

[0250] For the “Radiant Panel Test,” the sample comprised two pieces ofINSULFAB 2000A that had dimensions of approximately 13 inches by 21inches (33.0 cm by 53.3 cm) and fire barrier and non-woven web piecesthat had dimensions of approximately 12 inches by 20 inches (30.5 cm by50.8 cm), and the overhanging edge of the INSULFAB 2000A layers wasapproximately 0.5 inches (1.3 cm). For the “Burnthrough Test,” thesample comprised two pieces of INSULFAB 2000A that had dimensions ofapproximately 34 inches by 38 inches (86.4 cm by 96.5 cm) and firebarrier and non-woven web pieces that had dimensions of approximately 32inches by 36 inches (81.3 cm by 91.4 cm), and the overhanging edge ofthe INSULFAB 2000A layers was approximately 1.0 inch (2.5 cm). Thesamples were tested according to the “Radiant Panel Test” and“Burnthrough Test” procedures described above and passed the tests.

Example 6

[0251] Example 5 was repeated with the following modification: twolayers of 3M™ THINSULATE™ ACOUSTIC INSULATION AU 4020-6 material werepositioned on one side of the fire barrier material. The resultingthermal acoustic insulation blanket samples passed the “Radiant PanelTest” and the “Burnthrough Test”.

Example 7

[0252] Example 5 was repeated with the following modification: 3M™NEXTEL™ Flame Stopping Coated Paper was used in place of 3M™ NEXTEL™Flame Stopping Dot Paper. The resulting thermal acoustic insulationblanket was tested and passed the “Burnthrough Test”.

[0253] The referenced descriptions contained in the patents, patentdocuments, and publications cited herein are incorporated by referenceas if each were individually incorporated. Various unforeseeablemodifications and alterations to this invention will become apparent tothose skilled in the art without departing from the scope and spirit ofthis invention. It should be understood that this invention is notintended to be unduly limited by the illustrative embodiments andexamples set forth herein and that such examples and embodiments arepresented by way of example only, with the scope of the inventionintended to be limited only by the claims set forth herein as follows:

We claim:
 1. An insulation blanket comprising (a) substantiallyhydrophobic insulation material; and (b) high temperature-resistantmaterial; with the proviso that said blanket is casing-free.
 2. Theblanket of claim 1 wherein said substantially hydrophobic insulationmaterial comprises at least one polymer.
 3. The blanket of claim 2wherein said polymer is a polyolefin.
 4. The blanket of claim 1 whereinsaid substantially hydrophobic insulation material is fibrous.
 5. Theblanket of claim 1 wherein said high temperature-resistant material is aflame-resistant material.
 6. The blanket of claim 1 wherein said hightemperature-resistant material is a material that is both flamepropagation-resistant and flame penetration-resistant, or that isburnthrough-resistant.
 7. An insulation blanket comprising (a) fibrous,substantially hydrophobic insulation material comprising polyolefin; and(b) a material that is both flame propagation-resistant and flamepenetration-resistant, or that is burnthrough-resistant; with theproviso that said blanket is casing-free.
 8. An insulation blanketcomprising (a) substantially hydrophobic insulation material comprisingat least one polymer; and (b) a material that is both flamepropagation-resistant and flame penetration-resistant, or that isburnthrough-resistant; said materials being encased within a protectivecovering.
 9. A process for producing an insulation blanket, the processcomprising the step of continuously bringing together, optionally in thepresence of one or more intervening or adjacent materials, at least oneinsulation material and at least one high temperature-resistantmaterial.
 10. The process of claim 9 wherein said insulation materialcomprises substantially hydrophobic insulation material.
 11. The processof claim 9 wherein said insulation material comprises at least onepolymer.
 12. The process of claim 10 wherein said substantiallyhydrophobic insulation material comprises at least one polymer.
 13. Theprocess of claim 11 or claim 12 wherein said polymer is a polyolefin.14. The process of claim 9 or claim 10 wherein said insulation materialis fibrous.
 15. The process of claim 9 wherein said hightemperature-resistant material is a flame-resistant material.
 16. Theprocess of claim 9 wherein said high temperature-resistant material is amaterial that is both flame propagation-resistant and flamepenetration-resistant, or that is burnthrough-resistant.
 17. A processfor producing an insulation blanket, the process comprising the step ofcontinuously bringing together, optionally in the presence of one ormore intervening or adjacent materials, at least one fibrous,substantially hydrophobic insulation material comprising polyolefin andat least one material that is both flame propagation-resistant and flamepenetration-resistant, or that is burnthrough-resistant.
 18. Aninsulation blanket produced by the process of claim 9, wherein saidmaterials are in the form of layers that are substantially coextensive.19. The blanket of claim 18, wherein said insulation material ispolymeric.
 20. The blanket of claim 19, wherein said polymericinsulation material is fibrous.
 21. An insulation blanket produced bythe process of claim 17, wherein said materials are in the form oflayers that are substantially coextensive.
 22. A process for insulatinga surface, the process comprising the step of providing said surfacewith the insulation blanket of claim 1, claim 7, claim 8, claim 18, orclaim 21.